DODGE RAM 2003 Service Repair Manual

power in off road situations. Low range reduction
ratio is 2.72:1.
SHIFT MECHANISM
The transfer case is operated by an adjustable floor
mounted shift linkage. The transfer case shift lever
is directly attached to the shift sector. The sectoroperates the range and mode forks within the trans-
fer case.
A straight line shift pattern is used with a NEU-
TRAL detent. Lever range positions are imprinted in
the shift knob.
SHIFTING
The transfer case can be shifted between the 2H
and 4H operating ranges while the vehicle is in
motion. The vehicle must have the transmission
placed in NEUTRAL, or the clutch depressed in the
case of a manual transmission, and be moving less
than 2-3 MPH when shifting into and out of the 4L
operating range.
DIAGNOSIS AND TESTING - TRANSFER CASE -
NV241 GENII
Before beginning repair on a suspected transfer
case malfunction, check all other driveline compo-
nents beforehand.
The actual cause of a problem may be related to
such items as: front hubs, axles, propeller shafts,
wheels and tires, transmission, or clutch instead. If
all other driveline components are in good condition
and operating properly, refer to the Diagnosis Chart
for further information.
DIAGNOSIS CHART
Condition Possible Cause Correction
Transfer Case difficult to shift or will
not shift into desired range.1) Vehicle speed too great to permit
shifting.1) Stop vehicle and shift into
desired range. Or, reduce speed to
below 3-4 km/h (2-3 mph) before
attempting the shift.
2) If vehicle was operated for an
extended period in 4H on a dry
paved surface, the driveline torque
load may be causing a bind.2) Stop vehicle and shift the
transmission into neutral. Shift the
transfer case to 2H and operate
vehicle in 2H on dry paved
surfaces.
3) Transfer case external shift
linkage binding.3) Lubricate, repair, or replace
linkage bushings, or tighten loose
components as necessary.
4) Insufficient or incorrect lubricant. 4) Drain and refill to edge of fill hole
with MoparTATF +4, Automatic
Transmission fluid.
5) Internal components binding,
worn, or damaged.5) Disassemble the transfer case
and replace worn or damaged
components as necessary.
Transfer Case noisy in all operating
ranges.1) Insufficient or incorrect lubricant. 1) Drain and refill to edge of fill hole
with MoparTATF +4, Automatic
Transmission fluid.
Fig. 2 Transfer Case - Rear View
1 - TRANSFER CASE
2 - IDENTIFICATION TAG
21 - 592 TRANSFER CASE - NV241 GENIIDR
TRANSFER CASE - NV241 GENII (Continued)

Condition Possible Cause Correction
Noisy in, or jumps out of, four wheel
drive low range.1) Transfer case not completely
engaged in 4L position.1) With the transmission in
NEUTRAL, or the clutch depressed
in the case of a manual
transmission and the vehicle moving
under 3-4 km/h (2-3 mph), shift the
transfer case to NEUTRAL and then
shift into the 4L position.
2) Shift linkage out of adjustment. 2) Adjust linkage.
3) Shift linkage loose or binding. 3) Tighten, lubricate, or repair
linkage as necessary.
4) Range fork damaged, inserts
worn, or fork is binding on the shift
rail.4) Disassemble unit and repair as
necessary.
5) Low range gear worn or
damaged.5) Disassemble unit and repair as
necessary.
Lubricant leaking from output shaft
seal or vent.1) Transfer case overfilled. 1) Drain lubricant to the correct
level.
2) Vent closed or restricted. 2) Clear or replace vent as
necessary.
3) Output shaft seals damaged or
installed incorrectly.3) Replace seal as necessary.
Check to ensure that another
component, the propeller shaft slip
yoke for example, is not causing
damage to seal.
Abnormal tire wear. 1) Extended operation on hard, dry
surfaces in the 4H position.1) Operate vehicle in the 2H
position on hard, dry surfaces.
REMOVAL
(1) Raise and support vehicle.
(2) Remove skid plate, if equipped. (Refer to 13 -
FRAMES & BUMPERS/FRAME/TRANSFER CASE
SKID PLATE - REMOVAL)
(3) Position drain oil container under transfer
case.
(4) Remove transfer case drain plug and drain
lubricant into container.
(5) Disconnect vent hose and transfer case position
sensor connector.
(6) Disconnect shift rod from grommet in transfer
case shift lever, or from floor shift arm whichever
provides easy access. Use channel lock style pliers to
press rod out of lever grommet.
(7) Support transmission with jack stand.
(8) Mark front and rear propeller shafts for assem-
bly reference.(9) Remove front and rear propeller shafts. (Refer
to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER
SHAFT/PROPELLER SHAFT - REMOVAL)
(10) Support transfer case with suitable jack.
Secure transfer case to jack with safety chains.
(11) Remove nuts attaching transfer case to trans-
mission.
(12) Move transfer case assembly rearward until
free of transmission output shaft.
(13) Lower jack and move transfer case from
under vehicle.
DISASSEMBLY
Position transfer case in a shallow drain pan.
Remove drain plug and drain any remaining lubri-
cant remaining in case.
DRTRANSFER CASE - NV241 GENII 21 - 593
TRANSFER CASE - NV241 GENII (Continued)

SHIFT LEVER AND FRONT OUTPUT SHAFT SEAL
(1) Shift transfer case into NEUTRAL.
(2) Remove nut that retains the shift lever to sec-
tor shaft. Then remove shift lever from shaft (Fig. 3).
(3) Remove the front propeller shaft seal boot
retaining clamp (Fig. 4).
(4) Remove the front propeller shaft seal boot (Fig.
5).
(5) Remove the front output shaft seal slinger by
bending (Fig. 6) the slinger ears away from the
transfer case.
Fig. 4 Remove Boot Clamp
1 - SEAL BOOT
2 - BOOT CLAMP
Fig. 5 Remove Seal Boot
1 - SEAL BOOT
2 - SEAL SLINGER
Fig. 6 Bend Slinger Ears
1 - SLINGER
2 - BEND UPWARD
Fig. 3 Remove Range Lever Nut
1 - RANGE LEVER
21 - 594 TRANSFER CASE - NV241 GENIIDR
TRANSFER CASE - NV241 GENII (Continued)

(6) Using a suitable pry tool (Fig. 7), remove the
slinger from the output shaft using care not to dam-
age the shaft.
(7) Using a screw and a slide hammer, remove the
front output shaft seal.
REAR EXTENSION
(1) Remove rear extension bolts (Fig. 8).(2) Remove rear extension housing (Fig. 9). Tap
extension once or twice with a plastic mallet to break
sealer bead and loosen it.
(3) Remove output bearing retaining ring with
heavy duty snap-ring pliers (Fig. 10).
Fig. 7 Remove Slinger From Shaft
1 - SLINGER
2-PRYTOOL
Fig. 8 Remove Rear Extension Bolts
1 - EXTENSION HOUSING
2 - TRANSFER CASE
Fig. 9 Remove Rear Extension
1 - EXTENSION HOUSING
2 - TRANSFER CASE
3 - PRY SLOT
Fig. 10 Remove Output Shaft Retaining Ring
1 - REAR OUTPUT SHAFT
2 - OUTPUT SHAFT BEARING
3 - RETAINING RING
4 - TRANSFER CASE
DRTRANSFER CASE - NV241 GENII 21 - 595
TRANSFER CASE - NV241 GENII (Continued)

OIL PUMP AND REAR CASE
(1) Remove rear case-to-front case bolts (Fig. 11).
(2) Loosen rear case with pry tool to break sealer
bead. Insert tool in slot at each end of case (Fig. 12).(3) Unseat rear case from alignment dowels.
(4) Remove rear case and oil pump assembly from
front case (Fig. 13).
CAUTION: Do not remove the bolts holding the oil
pump cover to the rear case half. The oil pump
cover is aligned to the rear output shaft bearing
inner race and will become mis-aligned if the bolts
are loosened. If the transfer case failure has gener-
ated any debris which may have become trapped in
the oil pump, the rear case and oil pump assembly
MUST be replaced.
FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Remove shift rail cup and spring (Fig. 14).
Fig. 11 Remove Case Bolts
1 - REAR CASE
2 - FRONT CASE
3 - BOLT
Fig. 12 Loosen Case Halves
1 - REAR CASE
2 - FRONT CASE
3 - PRY SLOTS
Fig. 13 Remove Rear Case
1 - REAR CASE
2 - FRONT CASE
Fig. 14 Shift Rail Cup And Spring Removal
1 - SHIFT RAIL
2 - SPRING
3 - CUP
21 - 596 TRANSFER CASE - NV241 GENIIDR
TRANSFER CASE - NV241 GENII (Continued)

(2) Remove front sprocket retaining ring (Fig. 15).
(3) Pull mainshaft, front sprocket and chain out-
ward about 25.4 mm (1-inch) simultaneously (Fig.
16).
(4) Remove chain from mainshaft drive sprocket
and remove front sprocket and chain as assembly.SHIFT FORKS AND MAINSHAFT
(1) Remove the transfer case position sensor (Fig.
17).
(2) Loosen detent plug.
(3) Remove detent plug, spring, and plunger (Fig.
18). Note that the plug has an O-ring seal. Remove
and discard this seal.
Fig. 15 Removing Front Sprocket Retaining Ring
1 - FRONT SPROCKET
2 - RETAINING RING
3 - FRONT OUTPUT SHAFT
Fig. 16 Remove Front Sprocket and Drive Chain
1 - FRONT DRIVE SPROCKET
2 - DRIVE CHAIN
3 - MAINSHAFT
Fig. 17 Remove Position Sensor
1 - FRONT CASE
2 - POSITION SENSOR
Fig. 18 Remove Detent Plug, Spring, and Plunger
1 - FRONT CASE
2 - DETENT PLUG
3 - DETENT SPRING
4 - DETENT PLUNGER
DRTRANSFER CASE - NV241 GENII 21 - 597
TRANSFER CASE - NV241 GENII (Continued)

(4) Remove the front output shaft snap-ring (Fig.
19).
(5) Remove front output shaft from bearing in case
(Fig. 20).(6) Pull mainshaft assembly out of input gear,
mode sleeve, and case (Fig. 21).
(7) Remove mode fork, mode sleeve, and shift rail
as assembly (Fig. 22). Note which way the sleeve fits
in the fork (long side of sleeve goes to front).
Fig. 19 Remove Front Output Shaft Snap-ring
1 - FRONT OUTPUT SHAFT
2 - SNAP-RING
Fig. 20 Remove Front Output Shaft
1 - FRONT CASE
2 - FRONT OUTPUT SHAFT
Fig. 21 Remove Mainshaft
1 - FRONT CASE
2 - MAINSHAFT
Fig. 22 Remove Mode Fork and Shift Rail
1 - MODE FORK
2 - SHIFT RAIL
3 - MODE SLEEVE
21 - 598 TRANSFER CASE - NV241 GENIIDR
TRANSFER CASE - NV241 GENII (Continued)

(8) Remove range fork retaining ring.
(9) Remove range fork and hub as an assembly
(Fig. 23). Note fork position for installation reference.
(10) Remove the shift sector support (Fig. 24).
(11) Remove shift sector (Fig. 25).
MAINSHAFT
(1) Remove the drive sprocket retaining ring (Fig.
26) from the output shaft.
(2) Remove the drive sprocket thrust washer (Fig.
27) from the output shaft.
Fig. 23 Range Fork And Hub Removal
1 - RANGE HUB
2 - RANGE FORK
Fig. 24 Remove Sector Support
1 - SECTOR SUPPORT
2 - FRONT CASE
3 - SECTOR SHAFT
Fig. 25 Remove Shift Sector
1 - SHIFT SECTOR
Fig. 26 Remove The Drive Sprocket Retaining Ring
1 - OUTPUT SHAFT
2 - RETAINING RING
3 - DRIVE SPROCKET
Fig. 27 Remove Drive Sprocket Thrust Washer
1 - OUTPUT SHAFT
2 - THRUST WASHER
3 - DRIVE SPROCKET
DRTRANSFER CASE - NV241 GENII 21 - 599
TRANSFER CASE - NV241 GENII (Continued)

(3) Remove drive sprocket (Fig. 28) from the out-
put shaft.
(4) Remove the clutch gear (Fig. 29) and hub (Fig.
30) from the output shaft.
(5) Remove the mode hub retaining ring (Fig. 31)
from the output shaft.
(6) Remove the mode hub (Fig. 32) from the output
shaft.
INPUT AND PLANETARY GEAR
(1) Remove input gear seal with suitable screw
and slide hammer.
(2) Remove input gear retaining ring (Fig. 33) with
heavy duty snap-ring pliers.
(3) Place front case in horizontal position. Then
remove input gear and low range gear as an assem-
Fig. 28 Remove Drive Sprocket
1 - OUTPUT SHAFT
2 - DRIVE SPROCKET
Fig. 29 Remove Clutch Gear
1 - OUTPUT SHAFT
2 - CLUTCH GEAR
3 - MODE HUB
Fig. 30 Remove Sprocket Hub
1 - OUTPUT SHAFT
2 - SPROCKET HUB
Fig. 31 Remove Retaining Ring
1 - OUTPUT SHAFT
2 - RETAINING RING
3 - MODE HUB
Fig. 32 Remove Mode Hub
1 - OUTPUT SHAFT
2 - MODE HUB
21 - 600 TRANSFER CASE - NV241 GENIIDR
TRANSFER CASE - NV241 GENII (Continued)

bly (Fig. 34). Tap gear out of bearing with plastic
mallet, if necessary.
INPUT AND PLANETARY GEAR
(1) Remove snap-ring that retains input gear in
low range gear (Fig. 35).
(2) Remove retainer (Fig. 36).
Fig. 35 Input Gear Snap-Ring Removal
1 - INPUT GEAR SNAP-RING
Fig. 36 Input Gear Retainer Removal
1 - INPUT GEAR
2 - LOW RANGE GEAR
3 - RETAINER
Fig. 33 Remove Input Gear Retaining Ring
1 - INPUT GEAR
2 - RETAINING RING
Fig. 34 Remove Input Planetary Assembly
1 - FRONT CASE
2 - INPUT PLANETARY ASSEMBLY
DRTRANSFER CASE - NV241 GENII 21 - 601
TRANSFER CASE - NV241 GENII (Continued)